1996 - 2003 Polaris Sportsman Xplorer 500 ATV service manual
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Service manual for the 1996 to 2003 Polaris Sportsman Xplorer 500 ATV or quad.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed with photos and illustrations to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your ATV working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your ATV or Quad.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an ATV yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an ATV at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your ATV at arms reach is the fact that most problems associated with a ATV are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: carburettor kits, oil filters, pistons, gaskets, brakes, sprockets, chains, wheel bearings, tires, tyres, lamps, bulbs, guards, gearbox, throttle, handlebar, seat, rack, start, kill, switch, button, tank, fuel, gasoline, petrol, diesel, quad, polaris, Yamaha, rings, wheels, steering, wheels, electrical, suspension, exhaust, body, muffler, drivetrain, con rod, cdi, filter, spark plug, radiator, starter, stator, water pump, recoil, thermostat, intake, head, cams, clutch, cv joint, drive belt, transfer case, chain, sprocket, hub, diff, differential, pegs, cover, guards, skid plate, decals, oil tank, scoop and much more.
As with any product in your home, the average ATV may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good ATV and purchase an over the top model that is not really used to its fullest capacity. While the cost of ATVs has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every ATV will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your ATV giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages: 504
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
This official service repair manual gives complete step by step information on repair, servicing and preventative maintenance. The official manual is highly detailed with photos and illustrations to help guide you through every repair and troubleshooting procedure. This manual contains all you need to know to keep your ATV working right and is the only service repair manual you will need. It will help you understand, care for, and lower the repair and maintenance cost for your ATV or Quad.
With the abundance of service oriented companies provided in the global economy today, added with the addition of a fast paced, throw away society, repairing an ATV yourself may seem like a waste of time and money. With that said, the cost effectiveness and pride that comes with repairing an ATV at your home can be one of the greatest feelings in the world. This can be easily done with this official repair manual at your disposal, and a minimal amount of time and space.
The first and foremost benefit of having a repair manual for your ATV at arms reach is the fact that most problems associated with a ATV are simple and easy fixes. With all products, the manual will have a section that gives you many options on symptoms of the problem, and a troubleshooting method to go along with the issues at hand. The simple repairs included in this section can not only save you a large amount of money in repair and replacement costs, but also give you the added benefit of immediate results without the time having to be spent either taking it to the repair shop, or going to your local dealer to purchase a new product.
A small sample of some of the topics covered in this manual are: carburettor kits, oil filters, pistons, gaskets, brakes, sprockets, chains, wheel bearings, tires, tyres, lamps, bulbs, guards, gearbox, throttle, handlebar, seat, rack, start, kill, switch, button, tank, fuel, gasoline, petrol, diesel, quad, polaris, Yamaha, rings, wheels, steering, wheels, electrical, suspension, exhaust, body, muffler, drivetrain, con rod, cdi, filter, spark plug, radiator, starter, stator, water pump, recoil, thermostat, intake, head, cams, clutch, cv joint, drive belt, transfer case, chain, sprocket, hub, diff, differential, pegs, cover, guards, skid plate, decals, oil tank, scoop and much more.
As with any product in your home, the average ATV may come across a point in time when a more serious repair is needed. Many people in todays society will go and trade in a perfectly good ATV and purchase an over the top model that is not really used to its fullest capacity. While the cost of ATVs has gone down over the years, the repair kits and parts for the models are a fraction of the cost, and can easily installed with the proper repair manual. This manual will provide step by step instruction on disassembly, repair methods, and illustrations related to the repair. With this knowledge at your disposal, when the next issue comes up, you will have the knowledge and experience to fix the problem with ease.
In the end, you have a simple choice to make. You can be well informed, and pro active in your life by having the skill and drive to repair the items in your home using something as simple as a few inexpensive parts, a little time, and a good repair manual, or you can go about your way spending absurd amounts of money to purchase a product that will come across the same problem at some time or another, providing you with a never ending cycle of spending your hard earned money. At some point, every ATV will have an issue, as a machines quality is measured solely by the users commitment to maintenance. A good way to keep your ATV giving you years of quality service without having years of service bills is to purchase a good repair manual, and learn to do it yourself.
Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
Notes, cautions and warnings throughout each chapter pinpoint critical service information.
Numbered instructions guide you through every repair procedure in a step-by-step fashion.
Bold figured numbers help you quickly match illustrations with instructions.
Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
Numbered table of contents easy to use so that you can find the information you need fast.
Manual Language: English
File Format: PDF
File Delivery: PDF (Instant Download)
Pages: 504
To purchase this repair manual just click on the green instant download button at the upper left hand corner of this page. After purchasing just download it to your computer to save it and print pages from it whenever you need it.
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Automated PDF to Text preview page 4 to 6:
CHAP TER FOURTEEN . BRAKES Disc brakes Front brake pad replacement Fro nt cal iper Ou tput sha ft brake pad replacement (1996-1997 mode ls) O utput sha ll brake cal iper ( ]996- 1997 mode ls) Outpu t sha ll brake pad repl acement ( I998- on models) Output shaft brake caliper (I 998 -on mode ls) .. . .. . . 382 Front master cylinder Rear master cylinder Brak e hose replace ment Rear brake peda l Rem brake lever ( 1996 -1997 Sweden mod els) Foot brak e (199 8-on Sw eden model s) Brake d isc Bleeding the sys te m CHAPTER FIFTEEN BODY Seat Radiator guard Rear rack . . . .. .. .. . 425 Front rack and grille Side panels Front fender Fro nt bum per (models so eq uipped ) Rear fender Footv..'ells Rear bump er (mode ls so eq uipped) SUPPLEMENT . 2001-2003 SERVICE INFORMATION Starting the engine . . . . . . . . . . . 437 Transmission Lighting system Electrical components Stee ring sha ll (2002-on mode ls) Rear hub and bearing carrier (200 3 mode ls) Rear brake pad replacement (2003 models) Rear ca lipers (200 3 mod els) Ignition system Periodic maintenance Engine tUIl C- Up Cy linde r block Piston and piston rings Engine Flywhee l and stator plate Carburetor (Sportsman 500 H.G. models) Front master cylinder Rear master cylinder (2003 models) Rea r brake disc (200 3 mode ls) Brak e hose replace men t (2003 models) Cleaning and inspection Carburetor tests and adjustments Drive belt Driv en pulley (200 3 mod els bui lt afte r 07/08102) INDEX . .470 .476 WIRING DIAGRAMS . QUICK REFERENCE DATA ATV INFORMATION MODEL: VIN NUMBER:, ENGINE SERIAL NUMBER : CARBURETOR SERIAL NUMBER OR 1 MARK: .0. YEAR: _ _ _ _ TIRE INFLATION PRESSURE (COLD)' Model Front wheels Rear wheels kPa 34.5 34.5 PSI 5 5 "Tlre pressure for original equipment tires. Aftermarket tires may require different Inflation pressure. RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES Item Engine 011 Transmission all Lubricant or fluid type Polaris Premium 4 Synthetic 10W/4Q or 10W/40 motor all Polaris synthetic gear case 011 (part No. 2871478) Polaris front gearcase lube (part No. 2871653), or API GL5 80·90 gear lube Polaris demand drive hub fluid (part No. 2871654), or ATF Type F. DOT 3 brake fluid 50:50 mixture ethylene glycol·based coolant compounded for aluminum radiators and engines Polaris all season grease, or equivalent Front gear case Front hubs Brake fluid Coolant Grease RECOMMENDED CAPACITIES Item Engine all Transmission all Front gear case (all years) Front hubs Coolant Quantity 1.89 L (2 U.S. qts.) 946.3 cc (32 U.S. oz.} 96 cc (3.25 U.S. oz.) 75 cc (2.5 U.S. oz.) Approx. 2.16 L (2.25 U.S. qts.) IX MAINTENANCE AND TUN E·UP T ORQ UE SPECIFICATIONS Item Crankcase oil drain plug Cylinder head cover screws Front gear case drain plug Handlebar up per holder bol ts Oi l tank drain plug N'm 19 8.2 9.4 13·17 19 20 6-7 21 21 in... lb. 72 83 115-150 ft.· lb. 14 0 11 tank screen and fitting Valve adjuster locknuts Whee/lug nuts 14 15 53-62 Front Rear 15 15 MAINTENANCE AND TUNE·UP SPEC IF IC AT IO NS Item Disc brake pad thickness wear limit 2003 Sportsman 500 & 500 H.O. Spec ific at ion Rear brake All other models and years Front and rear brakes Valve clearance (cold) Intake and ex haust Spark plug 4.6 mm (0.180 In.) 3.8 1 mm (0.150 In. ) 0.15 mm (0.006 In .) 400 cc Heat range Gap 500 ee Heat range 1996-1997 1998-200 1 2002·on Gap 1996 · 1998 1999-2000 200 1·on Idle sp eed 1996-1988 , 2001-on 1997·2000 Carburetor pilot air screw (34 mm) 1996 1997·1998 1999-2000 2001-on (400 ee) Carburetor pilot air screw (40 mm ) 2001 2002-on NG K BKR 5E 0.9 mm (0.036 in.) NGK BKR5ES NGK BKR5E NGK BKR6E 0.6-0.7 mm (0.02 4-0.028 in . 0.7 mm (0.028 In.) 0.9 m m (0.036 in.) 1100-1300 rpm 1000-1400 rpm 1 1/2 turns ou t 2 turns out 2 5/8 turns out 23/4 turns out 2 1/2 turns out 2 turns out REPLACE MENT BULBS Item Headlights Grill mounted lights 1996 1997 1998-on Taillight Brake light Indicator lights 1996 1997-on Spec ificati on 12 volt , 60/60 watt Halogen 12 12 12 12 12 volt , 37.5 watt (2) volt, 35 watt (2) volt, 27 watt volt, 8.26 watt volt , 6 .9 watt 12 volt , 1.25 wa tt 12 volt,l.0 watt x |
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